Roofing: Chapter-Ix

CHAPTER-IX
ROOFING
CHAPTER-IX
ROOFING
901 902 903
ROOFING WITH ASBESTOS CORRUGATED SHEETS ROOFING WITH MANGLORE TILES
REPAIR TO LEAKY TERRACE ROOFS AND WATER PROOFING OF NEW TERRACE ROOFS 904 905 906 BRICK BAT COBA ASBESTOS FLAT SHEETS CEILING JACK ARCHES
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SPECIFICATION NO. 901 ROOFING WITH ASBESTOS CORRUGATED SHEETS
1. 2. 3. 4. 5. 6. 7. 8.
Specification Strength Cutting and drilling where necessary Fixing Cutting And Drilling Where Necessary Manufacturers' Instructions Safety Precautions Handling and Storage at Site
Steno/var/www/apps/conversion/current/tmp/scratch21919/98731759.doc
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SPECIFICATION NO. 901 ROOFING WITH ASBESTOS CORRUGATED SHEETS

Specifica tion CR Specificati on No. 901 (para 1)
1. Asbestos corrugated roofing sheets and ridges shall be of specified manufacture and of lengths as shown on the drawings. Purlin spacing will be so designed as to enable the most economic use of standard manufactured lengths. The ridge purlins should be fixed at 8 cm to 11 cm from the apex of the roof. A. C. sheet shall conform to IS: 4591970 or as updated time to time.
Strength
2. The roofing sheets shall be capable of withstanding a distributed test load of 400 kg. per square metre with purlins spaced at upto 1.7 m. Centre. 3.1. Asbestos cement materials shall be cut with a wooden saw and drilled with brace and twist drill and the holes shall on no account be punched as this will not only splay out the aperture but also weakening the materials at vulnerable points, this is also likely to commence a fracture of the sheet which will ultimately open out in weathering. The holes shall be 2 mm larger than the diameter of the fixing bolts and shall always be drilled through the crown of the corrugations and never on the flats or valleys. 3.2. The holes for fixing the sheets shall be drilled in the exact position to suit the purlins, i.e. on the centre line of the purlins, if these are of timber and square head coach screws are used, or as close as possible to back of the purlins if J or L bolts are used with steel angles or precast concrete or timber purlins. To achieve this object, it is necessary to drill the holes on the roof after the sheeting is put in the correct position. 3.3. To avoid fracture, sheets must not be rigidly fixed. The purlins supporting sheets should be in one plane. 3.4. Screws and hooks should be supplied with cupshaped or limpet washers by approved manufacturers. It is also essential to make the bolt-holes watertight by using bitumen
CR Specificati on No. 901 (para 2) Western Railway Specifi cation
Cuttin g and drilli ng where necess ary
Holes
Western Railway Specifi cation
CR Specificati on No. 901 (para 5) CR Specificati on No. 901 (para 8)
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washers.
Fixing
4. The method of fixing shall be as per manufacturer's instructions which must be called for before erection is started. Joints should have a half corrugation lap only. The end lap should be 15 cm. Where four sheets meet at a lap, mitering of sheets is necessary to provide a snug fit. The maximum free overhang at the eaves should not exceed 40 cm. If a building is in an exposed position and subject to driving winds and rains, it is advisable to commence laying Big Six Corrugated sheets from the end opposite to the direction of prevailing winds. 4.1. The satisfactory service of the roofing depends to a great extent upon the efficiency of fixing accessories. It Is therefore, important that particular attention is paid to the proper selection and use of fixing accessories. 4.2. Galvanized iron 'j' type hook bolts or cranked hook bolts, and nuts bearing on galvanized iron washers and bitumen washers shall be used for fixing sheets on angle iron purlins. 4.3. Galvanized iron 'L' type hook bolts and nuts bearing on galvanized iron washers and bitumen washers shall be used for fixing sheets on R. S. Joists, precast concrete or timber purlins. 4.4. Galvanized iron coach screw bearing on galvanized iron washers and bitumen washers shall be used for fixing sheets on timber purlins 4.5. Galvanized iron roof bolts and nuts bearing on galvanized iron flat washers and bitumen washers shall be used for stitching on the sheets, fixture like ridge capings, corner pieces, ventilators, north light curves etc. 4.6. Where sheets are laid on tubular purlins the fixing bolt should be designed to encompass at least half the tube periphery and precautions should be taken to prevent its rotation. Sections other than angles and tubes may require an
CR Specificati on No. 901 (para 3)
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adapted form of hook bolt. 4.7. Direct fixing of sheets to drilled metal frame work or by stud welding is undesirable as it tends to restrain movement of sheets. 4.8. It is essential that the bolt holes are made watertight by the use of bituminous felt washers in conjunction with suitable G. I. washers. Fixing bolts and screw shall be 8 mm or more in diameter and the nuts of the hook crank bolts (or heads of coach screw) shall bear on G. I. washer (flat, curved or diamond pattern) which in turn shall be embedded on bituminous felt washers. The screws or nuts shall be tightened sufficiently only to seat the bitumen washer over the corrugations so that natural movement in the sub-structure of the roof may not damage the sheeting. 4.9. The length of the 'J' bolt or crank bolt shall be 75 mm longer than the depth of purlin for single sheet fixing and 90 mm longer than depth of the purlin where two sheet over lap or where ridges or other accessories are to be fixed with the sheet. The minimum length of square head coach screw for timber purlins shall be 110 mm when corrugated sheet is laid it shall be 115 mm when semi-corrugated sheet is laid. The number and length of bolts and the number of bitumen washer and GI. Washer for A. C. sheets shall be as given below :TABLE (A) NUMBER AND LENGTH OF BOLTS AND NUMBER OF BITUMEN FELT AND G. I. WASHERS FOR CORRUGATED SHEET Sr. No Situation No. of bolt and Bituminous washers and G. I. washer Twice the number of Length of bolt
Western Railway Specification
(a) At horizontal
(end) laps of
Depth of purlin plus
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sheets. At eaves when filler pieces are used. At ridge when corrugated sheets and ridge piece are secured by the same bolt
sheets in one horizontal course.
90 mm
(b) At eaves when
filler pieces are not used. At ridge when corrugated sheets and ridge piece are not secured by the same bolt. purlin where horizontal laps do not occur
Twice the number of sheets in one horizontal course.
Depth of purlin plus 75 mm
(c) At intermediate
Twice the number of sheet in one horizontal course.
Depth of purlin plus 75 mm
TABLE (B) NUMBER AND LENGTH OF BOLTS AND NUMBER OF BITUMEN FELT AND G. I. WASHERS FOR SEMI-CORRUGATED SHEETS
Sr. Situation No
No. of bolt and Bituminous washers and G. I. washer
Length of bolt
(a) At horizontal
(end) laps of sheets. At eaves when filler pieces are used. At ridge when corrugated sheets and ridge piece are secured by the same bolt.
SHORT BOLTS: - Depth of The number of purlin plus sheets in one 75 mm horizontal course plus two.
LONG BOLTS :- Depth The number of purlin sheets in one 90 mm course less one.
of plus
(b) At
eaves when filler pieces are not used. At ridge when sheets and ridge piece are not secured by the same bolt.
Twice the Depth number of purlin sheets in one 75 mm horizontal course plus one. The number of Depth of
of plus
(c) At intermediate
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purlins where horizontal laps do not occur
sheet in one horizontal course plus one.
purlin plus 75 mm
4.10. The galvanized iron / flat washer shall generally be 25 mm in diameter and 1.6 mm thick with hole to suit the required size of fixing accessory and the bitumen washer shall be 35 in diameter and 1.5 mm thick with hole to suit the required size of fixing accessory. For other shapes of G. I. and bitumen washers of suitable size as approved by the Engineer may be used. 4.11. Rigid capping shall as far as possible, be secured to the ridge purlins by the same bolts which secure the sheeting. Other asbestos cement accessories such as barge boards, eaves filler pieces and apron flashing pieces, shall be secured either to the supporting structure or the sheeting by roofing bolts.
Cracke d Sheets
Western Railway Specific ation
5. All sheets and accessories found to be cracked after fixing shall be replaced by new ones. The cracked sheets so removed shall be salvaged by the contractor by cutting into smaller but sound lengths where ordered. Nothing extra shall be paid for such work. 5.1 Unless otherwise specified in the manufacturers' instructions, where 4 corners of sheets overlap, two of them MUST be mitred (cut off). 6.0. Asbestos Cement Sheets and accessories shall be laid in strict accordance with the manufacturer's instructions, which must be obtained before starting the work. Principal instructions for laying "Big Six" type corrugated sheets and "Trafford" type Semi-corrugated sheets are given below:6.1. The purlin spacing for covering shall not exceed 1.6 m. roof The
Mitres
Manufac turers' Instruc tions
Purlin Spacing
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spacing of rails for side cladding shall not exceed 1.9 m. Ridge purlins shall be fixed 75 mm to 100 mm from the apex of the roof.
Overhan g
6.2. Free overhang at eaves shall in no case be more than 40 cm. 6.3. All sheets shall be laid with their smooth side towards the weather.
Western Railway Specific ation Western Railway Specific ation Western Railway Specific ation
End Laps
6.4. The end laps ( i.e. horizontal laps) shall not be less than 15 cm for o roof having pitches of 21 1/2 or more. o For flatter (less than 21 1/2 pitch) o roofs and normal pitch (21 1/2 and above pitch) roof in position or severe exposure, the end laps shall be increased as instructed by the Engineer. 6.5. The sheets shall be laid with side lap of half a corrugation starting the laying from the side opposite that of prevalent winds in the monsoon (i.e. side laps shall be laid on the side facing away from the prevailing winds and rains). 6.6. All trafford sheets have one end marked 'TOP' on the smooth side of the sheet. This end must always point towards the ridge. The sheets shall be laid with a side lap of one corrugation the left hand SMALL corrugation of each sheet being covered, by the right hand corrugation of the next sheet. 6.7. The "Big Six" laid as under :sheets shall be
Side LapsCorruga ted Sheets (Big Six)
Semicorruga ted Sheets (Traffo rd)
LayingCorruga ted Sheets (Big Six )
The sheets shall be laid starting at the eaves either from left to right or right to left depending upon the prevailing direction of wind. If laid from left to right the first sheet shall be laid uncut, but the remaining sheets in the bottom row shall have the top left hand corners cut or mitred. The sheets in the second and other intermediate rows shall have the top left hand corner and the bottom right hand corner cut with the 7
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exception of the first sheet in each row which will have only the bottom right hand corner cut and the last sheet in each row which will have only the top left hand corner cut. The last or top row sheet will have the bottom right hand corner cut with the exception of the last sheet which shall be laid uncut. If the sheets are laid from right to left, the whole procedure shall be reversed. The "mitre" described above is necessary to provide a snug fit where 4 sheets meet at a lap. It is cut from a point 15 cm (or whatever the length of the end lap may be) up to the vertical side of the sheet to a point 4.50 cm along the horizontal edge. This cuttings shall be done with an ordinary wooden saw at site.
Semicorruga ted (Traffo rd)Shee ts
6.8. "The Trafford" sheets shall be laid either from right to left or from left to right depending on direction of prevailing wind, starting at the eaves. When starting from right to left, the first sheet shall be laid uncut but the remaining sheets in the bottom row will have the top right hand corner cut or mitred. The sheets in the second and other intermediate rows shall have both the top right hand corner and bottom left hand corner cut with the exception of the first sheet in each row, which shall have only the bottom left hand corner cut, and the last sheet in each row which shall have only the top right hand corner cut. The last or top row sheets shall have the bottom left hand corner cut with the exception of the last sheet which shall be laid uncut. If the sheets are laid from left to right the whole procedure shall be reversed. The "mitre" described above is necessary to provide a snug fit where 4 sheets meet at a lap. The length of the mitre is 15 cm (or whatever the length of the end lap may be) and the width is equal to the width of corruption.
Details
6.9.
Where possible, Manufacturers details should be
CR Specificatio
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n No. 901 (para 9)
supplied with roofing details in order to enable them to supply the correct lengths of hook and U bolts. 6.10. Duck boards or ladders should be used when fixing sheets. Note :Ridge are not interchangeable with different makes of sheets, and they must be obtained only from the maker of the particular sheeting.
CR Specificatio n No. 901 (para 10)
6.11. Other Asbestos Cement accessories such as Ridge Finials, Apron Pieces, Eaves Filler Pieces, North Light Curves, Cowl type Ventilators etc. should be fixed according to the instructions of the manufacturers.
Safety Precaut ions
7. Cat ladders or roof boards must invariably be used by men working on the roofs which will incidentally avoid damage to the roofing materials also. No unauthorised person shall be permitted access to any area over which the sheeting is being laid. Where, it is not possible to keep this area clear, the corner shall take necessary protective measures for the safety of the persons getting access to the area. 8.1. The asbestos cement sheets shall be handled and stores in the best possible manner so as not to damage the sheets in any way. All damage caused due to careless handling or storing shall be borne by the contractor. The sheets shall be stacked to a height of not more than one metre on firm and level ground laid on wooden battens according to the stacking methods specified by the manufacturers and protected from damage. When, they are stacked for any length of time they shall be stored under cover. 8.2. Asbestos cement materials of same variety and size shall be stacked together. Damaged materials shall not be stacked with sound materials. All damaged materials shall be salvaged as early as possible.
Handlin g and Storage at Site
f
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SPECIFICATION NO. 902. ROOFING WITH MANGLORE TILES.
1. General 2. Fixing of Battens 3. Laying 4. Quality 5. Setting 6. Drip moulding 7. Fixing 8. Maintenance by contractor 9. Rate 10. Use with flat tiles
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SPECIFICATION NO. 902. ROOFING WITH MANGLORE TILES.

Gener al
1. The whole of roof shall be covered with class AA (IS 654-1972 or as amended from time to time double channeled flat tiles of the Mangalore pattern of approved make. All tiles must thoroughly well burnt throughout of regular shape and uniform size sharp, even and free from winds, cracks, laminations, bends and flaws. The roofing tiles shall also be free from impurities like particles of stone, lime or other foreign materials visible to naked eye either on the surface or on the fractured face of the tile obtained. They must be approved colour (deep red) and ring clearly when struck. Tiles shall be of uniform colour and shall not absorb more than 16% of their dry weight when soaked in water for full 24 hours. 2.1. The teak wood battens of size 25 mm 50 mm shall be fixed over the rafter at the specified or designed spacing and nailed. The nails shall penetrate at least 2 cm in to the rafters. The battens shall extend at least over length of three spans between the rafters. The battens shall be mailed to the rafters by means of plain headed mails. Their length shall be extended only by means of butt joint. The joint shall occur only over the rafters. The joints of no two adjacent rows of battens shall come over the same rafter. 3. The titles should be laid fair and square, and breaking joint, that is, left channel of the upper tile shall lie in the right channel of that below, and they shall fit properly one to another with catches resting full against battens, of sizes and spacing as shown on the drawings or as may be required, and shall be exactly parallel to the eaves. Joints in battens should be butt joints which shall come only over the rafters. The tiles shall be laid from the eaves towards the ridge. 4. The tiles should be in every way equal to a specimen to be approved by the engineer before the work commences. The tiles should not absorb more than 20% of their weight of water when soaked for more than 24 hours.
Wester n Railwa y Specif icatio n
Fixin g of Batte ns
Wester n Railwa y Specif icatio n
Laying
CR Specifica tion No. 903 (para 2)
Quality
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Setting
5. All requisite hip, ridge and valley tiles should be of Mangalore or other approved pattern, and set in mortar with joints pointed in cement (with red lead as a colouring substance), and kept wet for 10 days to render the whole surface perfectly secure and water-tight. The eaves and ridge lines should be perfectly straight and parallel. 6. A groove shall be cut in walling to received the edge of tilling when it abuts against the walls, and a fillet of cement mortar shall be carefully filled in the same, and the joint made thoroughly water-tight. 7. The tiles at gable end or other exposed parts, such as over verandahs with no ceiling boards, or ceiling tiles where liable to be lifted by the wind, shall be fixed by wire underneath or by battens on the top, screwed down at intervals, as shall be ordered by the Engineer. All valleys shall be laid with galvanised iron sheets with a good tile overlap to ensure thorough waterproofing. 8. The contractor shall maintain and keep the entire roof water-tight throughout one whole monsoon, and 10 per cent of cost of the roof work should be retained from the Contractor's final bill, as security. 9. The rate for roof tilling shall include the provision and fixing of supporting battens. G.I. Sheet in valleys shall separately paid for. Battens required for fixing tiles (against wind etc.) shall be paid separately. 10. The flat tiles shall be immersed in water for two hours and then dried. The underside of the flat tiles shall be dipped in shell lime white wash of the consistency of cream and dried before they are used in work. The tile shall then be laid dry on battens, the top surface of the battens having first been painted with a coat of tar. Over the tiles shall be spread lime mortar of thickness 25 mm, and the Mangalore tiles fully embedded thereto without air space, the tiles breaking the joints of the flat tiles. The tile shall be laid from the caves towards the ridge. When full tiles are not necessary, half tiles manufactured for the purpose shall be used. laying of the tiles and the mortar shall go concurrently. Mangalore tiles should be sufficiently soaked in water before use. The roof shall be kept well watered for a week..
Drip mouldi ng
Fixing
Mainte nance by contract or
Rate
Use with flat tiles
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SPECIFICATION NO. 903. REPAIRS TO LEAKY TERRACE ROOFS AND WATER PROOFING OF NEW TERRRACE ROOFS.
1. 2. 3. 4. 5. 6. 7. 8.
General Repair To Leaky Terrace Roofs Repair To Leaky Terrace Roofs With Bituminous Emulsion Such As Colas Water Proofing With Indian Patent Stone Water Proofing With Broken Terrazzo Set In Composite Mortar Water Proofing With Flat Tiles Water Proofing With Tar Or Bitumen Water Proofing With Bitumen Emulsion Water proofing with poly films. Water proofing with poly membrane Water proofing with bituminous felts.
APPENDIX- A APPENDIX- B APPENDIX- C
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SPECIFICATION NO. 903. REPAIRS TO LEAKY TERRACE ROOFS AND WATER PROOFING OF NEW TERRRACE ROOFS.
CR Specificati on No. 904 (para 1) CR Specificati on No. 904 (para 1.1)
General
1. For more details refer works manual.
Repairs to Terrace Roofs-.Rep air To Leaky Terrace Roofs
2.1. If there are visible cracks in the concrete, holes should be made with a brace bit about 2 cm deep at every 15 cm. A mixture of 1 part neat cement plus 1/8 part freshly slaked lime and colas mixed to make a thick fluid, should be pumped into each hole with a garden syringe till the crack overflows. It may be necessary to pump in some more of the cement lime colas cream, if the edges of the cracks show, as the liquid in the cream is drawn off. The excess cement lime can be scraped off the roof in an hour or so, after the work is completed. 2.2. If the roof is porous, it should be cleaned of all fungus and slime and two solutions made as under :2.2.1. a solution of 0.08 kg bar soap, shredded and dissolved in 1 litre of boiling water and 2.2.2. a solution of 002 kg alum in litre of boiling water. These solutions should then be laid on alternately with whitewash brushes till the roof has had three coats of each. atleast twelve hours should elapse between each coat, and care must be taken not to work the wash up into bubbles when laying. For the best results, this work should be done when the roof is thoroughly dry, and if possible, in sunny weather.
CR Specificati on No. 904 (para 1.2) CR Specificati on No. 904 (para 1.2(1) CR Specificati on No. 904 (para 1.2(2)
Repair To Leaky Terrace Roofs With Bituminous Emulsion Such As Colas Cracks under 6 mm in width
3.1. (A): - The roof should be carefully examined for cracks and treated se follows :-(i) Cracks should be thoroughly cleaned and bitumen emulsion poured into them carefully with specially made cans till they are completely filled. The surplus bitumen should be scraped off from the surface. A strip of the terrace 8 cm to 10 cm wide on each side of every crack should be painted with bitumen emulsion. In this painted portion, a strip of dungaree cloth
CR Specificati on No. 904 (para 1.3(A)
(ii) (iii)
(iv)
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sufficiently wide to cover the painted portion should be pressed in firmly by band. (v) The strip should be allowed to dry.
CR Specificati on No. 904 (para 1.3(B)) CR Specificati on No. 904 {(para 1.3(B(i)}
(B) Cracks from 6 mm 12 mm in width:
(i) The cracks should be thoroughly cleaned and filled with layers of 1 part sand 1/8 part fine saw dust and bitumen emulsion till they are completely filled. The mixture should be stirred with. & rod and rammed tight. (ii) (iii) (iv) (v)
Same as in 'A' above.
3.2. After the filling of the cracks, the terrace should be thoroughly cleaned, and a coat of bitumen emulsion applied on the terrace including the portion of about 20 cm wide on all walls abutting on the terrace. The portion to be painted each time should be about 30 cm long and about 10 cm wide. The quantity of bitumen emulsion should be taken at 2 kg per square metre. 3.3. In the bitumen emulsion thus applied, a strip of dungaree cloth should be embedded firmly by hand to its full width. The cloth should be used in rolls which should be gradually unfolded to keep pace with the portion painted with the emulsion. 3.4. When one roll of cloth is finished, the next is laid with an overlap of about 15.0 cm on the previous roll after first painting the overlap with bitumen emulsion. The final roll, after cutting it (if necessary) to the width or length of the terrace remaining to be covered, is carried over all walls abutting on the terrace to a width of 20 cm. 3.5. Portions of cloth on all walls should be tucked in the walls and filled with a lean 1/8 send, 1/16 fat lime freshly slaked, 1/4 cement mix and printed with bitumen emulsion. 3.6. After the terrace is covered fully with cloth, another coat of bitumen emulsion or Asphalt 30/40 should be applied at about 2 kg per square metre. 3.7. On this surface, pea gravel (3 mm to 6 mm in gauge ) 3 should be applied uniformly at about 0.9 m per 100 square
CR Specificati on No. 904 (para 1.4)
CR Specificati on No. 904 (para 1.7) CR Specificati on No. 904 (para 1.8) CR Specificati on No. 904 (para 1.9)
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metres and rolled with a light roller. 3.8. A second cost of bitumen emulsion or asphalt 30/40 should be applied near the joint in the walls, where the cloth has been tucked in. Note : 1) When any patent bitumen emulsion other than 'COLBS' is used, Specification by its manufacturer should be followed.
(2) If the work of mater proofing is to be done in two or three layers of dungaree cloth, then the process is repeated by the plies of dungaree cloth being laid at right angles to the layers below.
Water Proofing With Indian Patent StonePreparation of Surface : -
4.1. As soon as the brick bat coba grading base laid permits, and before it is fully hardened, all dirt, laitance and loose aggregate must be removed from the top surface by scrubbing with a wire brush to such an extent, as to leave the coarse brick aggregate slightly exposed, The surface must be so roughened as to enable proper bond with topping of the Indian Patent Stone to be laid on it. 4.2. A mixture of fine and coarse aggregates shall be used for the Indian Patent Stone. The fine aggregate shall consist of hard granular coarse sand free from dust, salt, clay or vegetable matter, and must be of such a size that it will all pass through 6-3 mm sieve, and shall be graded from fine to coarser grains with the coarser grains predominating. The sand should be of such a structure that 95% at least will be retained with IS Sieve 2.36 mm and not more than 10% will pass through IS sieve 3.35 mm. The coarse aggregate must consist of clean angular stone chippings graded in sizes from 6 mm to 10 mm, and shall be free from any mud coating, dust, loan, clay or vegetable matter. All the coarse aggregate must pass through a 12.6 mm mesh.
Aggregates
Mix
4.3. The mixture used shall preferably be 1/2:1:1:2 (1/2 part freshly slaked fat lime, one part cement, one part sand and two parts coarse aggregate, all measures being made by volume), The amount of mixing water should not exceed 18 litres for each batch of mix which should be made of one bag of cement (weighing 60 kg), The concrete used for the work should be well mixed and turned over atleast 3 times in the dry state, and three timer in the wet state before laying. If fat lime of good quality is not available, the mix may be of 1 part cement, one part sand two parts coarse aggregate by volume, subject to the prior permission of the Engineer. 4.4. The consistency of the concrete for the waterproofing coat, should be the driest possible to work with the to and fro
Consistency
CR Specificati on No.
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904 (para 2.4)
movements of the straight edge, used in the leveling up to the 4 cm finished thickness.
Laying
4.5. Before placing and compacting this 4 cm .wearing coat, the base slab shall be thoroughly wetted just before the placing operations, and there should be no pools of water standing on the surface of the base. The laying of the 4 cm thick coat should be preceded by brooming into the surface of the slab, a thin coat of neat freshly prepared cement grout for a short distance ahead, and the topping of 4 cm should be immediately applied before the grouting has dried or hardened, and should be smoothened out to the finished surface level with a straight edge. 4.6. When the laying to the finished surface grade has been done, this topping should be compacted with a wooden fleet, the level being tested with a straight edge to detect high and low spots which must be eliminated immediately. Floating should then be done with a wooden flat, and this should be followed by hard steel trowelling after the concrete has hardened sufficiently to prevent any creaming up of fine material. The finish given by trowelling should be a smooth dense one free from any unevenness, defects and blemishes. On no account should dry cement or a mixture of sand and dry cement be sprinkled on the surface, to absorb excess moisture or to stiffen the mixture. Additional steel trowelling may be required after further hardening. 4.7. This finished surface should be protected from the sun and from quick drying-out. Also it should be protected from any damage or disturbance due to building construction operations in progress, and should if possible be covered over completely with wet hessian or cement bags, until the surface is hardened sufficiently to prevent it getting damaged by walking upon. It should than be covered with 2.5 cm thick layer of sand which should be watered frequently to keep it damp for the next 10 days. On no account should bunding or flooding with water be permitted 4.8. The patent stone flooring layer shall be laid in rectangular or square panels, no side of which exceeds 2 metre. The panels should be cast on the alternate bay system, the base being separated when laying the patent stone concrete, by well oiled stripe of wood or by oiled flat iron strips. After the rectangular panels have set, the separating strips which should be properly oiled before insertion should be gently removed, and the joint should be filled in with a proper patent expansion joint filler material, or with a, thick cream made of one part of freshly slaked fat lime, one part of fine saw-dust, 2 parts of fresh cement, and 2 parts of very fine sand, this mortar being made with water containing crude jaggery, together with fresh Cowdung in the requisite proportions. The pouring of this cream should be as a
Finishing
Curing
Jointing of Panels
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thick stiff cream, This cream should be poured in sufficient quantities to stand slightly proud of the general surface of the Indian Patent Stone, so that when the cream has dried up, shrinkage that results, will not cause the surface of the joint to be in my way below the general surface of the Indian Patent Stone. The vertical edges of the rectangles should be neatly marked on the surface of the cement with a trowel, before the concrete is set hard.
No ramming after 15 minutes laying Water Proofing With Broken Terrazzo Set In Composite Mortar
4.9. No ramming or tamping of the concrete should be permitted 15 minutes after it has first been wetted, as initial set will by then have taken place. 5.1. Before the course of broken terrazzo tiles is laid, brick bat coba should be laid on the terrace roof as per Specification No. 905 for Brick Bat coba Terrazzo tile pieces should then be laid as follows:
CR Specificati on No. 904 (para 2.9) CR Specificati on No. 904 (para 3.1)
5.2. Sand should be of the same size as used for cement mortar for plaster. The proportion of the mortar shall be 1 cement to 2 freshly slaked fat lime and 4 sand. The work consists of laying of a bed of the composite mortar over the brickbat coba grading to a thickness of 2-5 cm, and embedding as closely as possible on the surface, pieces of broken terrazzo tiles, so as to cover as much of the surface as possible, with pieces of tiles having maximum dimensions not greater than 10 cm, leaving only thin joints of mortar in between. Only such area at a time will be taken up for laying, as will enable the setting of tiles in the mortar before it has had time to fake initial set i.e. within 20 minutes of addition of cement. The tile pieces to be used should be soaked in water far 8 period of at least 12 hours before they are used. The surface of the brick bat coba should be thoroughly cleaned and wetted before mortar is laid. The mortar should be spread on the brickbat coba and tamped to make a dense layer. Tile pieces are to be worked into it as densely as possible leaving only thin joints between tiles. The composite mortar should be made by incorporating very homogeneously in the well ground lime mortar, the requisite cement. 5.3. Just before initial set takes place, the top surface shall be rolled lengthwise and crosswise so as to secure thorough compaction of the tile pieces and the composite mortar. In no case the lime cement mortar in joints should stand proud of the tile surface, and it should be just flush so as to provide continuous surface for water to flow. The top surface of the broken layer should be brought true to the required levels by using a straight
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edge. 5.4. After laying, the entire work should be left undisturbed and no workman should be allowed to walk over it for a period of atleast 7 days. It should be kept thoroughly wet and fully cured for 21 days.
Water Proofing With Flat Tiles CR Specificati on No. 904 (para 3.4)
6.1. Prior to laying hat tile course, brick bet coba should be laid on the terrace roof to specification No. 906 for Brick Bat Cobs. After six days of laying the Brick Bet Coba, hat tile layers should be laid as follows :6.2. On the brick bet coba coarse, two courses of flat tiles shall be laid in cement mortar 1 :3 mixed with crude oil. The cement and sand shall be first mixed dry. The cement will be weighed for each mix to ascertain its weight, in order to fix the quantity of non-volatile crude oil to be added, which should be 10% of the weight of cement. The dry mixture shall be worked up well with the required quantity of crude oil, and then water added and the mortar further well worked with the trowel. The tiles shall be laid first course diagonally and second coarse square to the parapet, thus breaking joint. The side joints of the tiles shall not be more than 6 mm thick set fully in mortar. The mortar layer bed over the roof slab and also between the tiles shall not be less than 10 mm finished thickness. The flat tiles shall be immersed in water for two hours before being used. The tiles shall be carried into chases in the roof parapet wads, and finished on the outside face flush with a 20 mm thick cement mortar band 1:3, neatly hushed with the parapet face. Where the roof abuts against the wall of a higher storey, the tiles shall be carried so as to overlap the extremity of the terrace bearing on the wall. 6.3. Before the Work dries up completely, the tile joints shall be raked out and pointed over with cement mortar 1:3 mixed with crude oil as indicated above. The joints shall be well robbed over with thin bar trowels and the excess of mortar scraped off, until the surface of the pointing attains a black polish and becomes hard. The work shall be kept thoroughly wetted until the mortar has set firm and hard. Watering shall be continued for three weeks after construction.
Water Proofing With Tar Or Bitumen Preparing Surface
7.1. This work shall generally be carried out in dry weather as the tar or bitumen will not stick properly to wet surfaces. 7.2. Before application of any treatment, the roof shall be thoroughly wire brushed and cleaned of all foreign matter. Cracks if any (in the case of old roofs), shall be repaired se specified. 7.3. Surface painting with tar or bitumen- Approved tar or bitumen heated to the temperature recommended by the
CR Specificati on No. 904 (para 5.1) CR Specificati on No. 904 (para 5.2) CR Specificati on No. 904 (para
19
CHAPTER-IX
5.3)
manufacturers according to the grade used, shall be applied evenly, at the rate of 2 kg per square metre leaving no bare patches. The specified temperature shall be maintained during application. Immediately the surface is coated and while the tar or bitumen is still hot, it shall be evenly blended with clean dry sand at the rate of 0.6 m3 per 100 square metre. The tar or bitumen layer shall also be applied on a width of 15.0 cm up parapets. Chimney stacks, etc. and taken well into rein water out lets and blinded with sand as described before. 7.4. Approved tar composition (such as Shalimar's Tarmastic No. 3) shall be heated to the temperature recommended by the manufacturers, and mixed with clean dry sand over a fire in proportion (by weight) of two parts of Tarmastic to one of send. The temperature while beating or mixing shall not exceed 150oC. The mixture shall be evenly spread on the roof at the rate of 4.5 kg per m2 and smoothened with a hot trowel. Any pinholes that may appear shall be closed up. The mixture shall also be applied to parapets, chimney stacks etc. for a height of 15.0 cm, the top edge being taken into a chase cut in parapets, etc. at that height from roof level. Rainwater outlets shall also be treated with the mixture applied all round. The chase shall be neatly filled up with cement mortar 1:3 flush with the face of the wall and allowed to set. The whole of the treated surface shall then be coated with Tarfix or other similar approved tar composition brushed at the rate of 0.8 Kg per m2, taking it over the cemented chase for neat appearance. Clean dry pea gravel or Bajri (5 mm to 6 mm gauge) shall be used for blinding Tarfix at the rate of 0.45 to 0.50 m3 per 100 square metres, tamped or rolled in. Loose blindage shall be removed by light brushing 24 to 36 hours after application. Flashings and rainwater outlets shall however be blinded with coarse sand. Where gravel or bajri is not available locally, coarse sand or stone grit may be used for the entire area.
Water Proofing With Bitumen Emulsion
8.1. The terrace should be thoroughly cleaned and the depressions if any made good with 1: 4 cement mortar.
CR Specificati on No. 904 (para 6.1) CR Specificati on No. 904 (para 6.2)
8.2. The coat of bitumen emulsion ("Colas" or its equivalent containing about 50% of asphaltic bitumen) should be applied over the terrace, including the portion of about 20 cm width on walls abutting on the terrace. Quantity of emulsion should be about 2 Kg per m2.
20
CHAPTER-IX
8.3. The surface should be blinded with coarse sand and extra send swept off with brooms. NOTE : Normally this treatment would serve for a period of about 3 years after which it may have to be repeated.
21
CHAPTER-IX
SPECIFICATION N0. 904. BRICKBAT COBA.

1. General
22
CHAPTER-IX
SPECIFICATION N0. 904. BRICKBAT COBA.
General
1. Brickbat coba layer shall have a minimum thickness of 8 cm and shall be laid in a slope of not less then 1 in 50 inclusive of any slope already given to the R.C.C. roof slab. The brick concrete shall consist of brickbats from well burnt but not over burnt bricks, 4 cm size and less. A mixture of 1 cubic metre of such broken bricks, and 0.4 cubic metre of freshly slaked lime with no sand, shall be laid over on the R.C.C. slab and then well beaten up with wooden ''Thapies" until thoroughly consolidated, by systematic lengthwise movement of two rows of labourers, positioned closely to each other, on the entire width of the roof. The beating shall continue until the brick jelly concrete is fully consolidated, the beating being done by movement of the two rows of beaters backward and forward, and until the "Thapi" makes no impression an the surface but readily rebounds from such surface when it is struck. During beating with "Thapies", the surface shall be periodically and liberally sprinkled with a mixture consisting of 3 1/2 kg of Gur and 2 kg 'Bael' fruit, boiled in 120 litres of water. As soon as the beating is complete, lime water should be sprinkled on the surface to soften it, and the mortar which will have trowelled to the surface, should then be well rubbed and trowelled smooth with a steel trowel. The surface during the process of beating should not be permitted to become so uneven that water can lodge in the depressions, and such unevenness should be made up by adding fresh brick concrete and beating down whereever necessary. This brickbat coba grading should be damp after beating, by covering with grass or mate for a period not less than 7 days, after which only the Indian Patent Stone shall be laid over it. The slope of the Indian Patent Stone surface should follow the slope of the brickbat coba grading, which, as stated above, should not be less than 1 in 50. Care should be taken that perished lime is not on any account used for the making of the brickbat coba jelly. 1.1. Water proofing layer of Indian Patent Stone should be laid on the brickbat coba grading as per Para 2 of specification No. 904 for Repairs to Leaky Terrace Roofs and Water-proofing of New Terrace Roofs.
CR Specification No. 905 (para 1)
23
CHAPTER-IX
SPECIFICATION NO. 905 ASBESTOS FLAT SHEETS CEILINGS
1. Specification 2. Cover strips 3. Payment.
24
CHAPTER-IX
SPECIFICATION NO. 905 ASBESTOS FLAT SHEETS CEILINGS

Specificatio n
1. Asbestos hat sheets for ceilings shall be of specified manufacture and thickness. 1.1. The sheets should be screwed on to the framework with 35 mm galvanized countersunk head screws 15 cm apart, leaving 6 mm clearance to joint edges to permit expansion and contraction of the timber without damaging the sheets. The screws in the adjoining sheets should be side by side and not staggered, and shall not be lees than 10 mm from the edge. Screws shall be uniformly and symmetrically placed over the entire surface. Fixing with screws shall be done from centre of boards outwards, and screws driven slightly below the board surface with care, so as not to project above the sheet surface. 2. The Asbestos Cover Skips to joints should be fixed by 6 cm copper or brass wood screws, 30 cm apart. Before fixing the cover strips, the gap between the joining sheets should be slightly grooved with a carpenter's file. It should be ensured, that the joint between the sheets comes square on the timber panelling. 3. The finished surface area is only to be paid for. No extra payment is to be made for cover strips, laps, etc.
CR Specificatio n No. 906 (para 1) CR Specificatio n No. 906 (para 2)
Cover strips
Payment.
25
CHAPTER-IX
SPECIFICATION NO. 906. JACK ARCHES.
1. 2. 3. 4. 5. 6. 7. 8.
Quality & Setting Against Metal Centering Painting Metal Surface Tie Rod Rise Laying Removal Of Centering Water Proofing
26
CHAPTER-IX
SPECIFICATION NO. 906. JACK ARCHES.

Quality & Setting Against Metal
1. In building jack-arches, only first class bricks are to be used. These shall be laid as specified for brick work in arches, and shall, unless otherwise specified, be laid in cement or lime mortar. Nevertheless, such bricks as make direct contact with the metal of joists, rails and beams, shall be set in cement mortar. 2. The centering may be erected on pillars built up from the ground, or may be suspended from the roof beams. In the latter case, the cross timbers carrying the centering shall be suspended from the OUTER flanges of the beams, by means of stout hookbolts of square section, to prevent the beams being displaced by the thrust of the arch due to the centering settling under its load. The top surfacing of the centering shall be covered with close boarding or be formed with impermeable clay, to prevent mortar running through the joints. The courses of brick work shall be marked out on the surface of centering, and the curvature, checked by means of template capable of application after completion. 3. All steel beams, tie rods, etc. shall be thoroughly freed from rust by means of wire-brushing. The portion of beams, tie rods and wall-plates which will remain exposed, shall be painted with two coats of red-lead paint before they are erected in position. The parts of roof beams, tie-rods and wall plates, which are to be embedded in masonry, shall be completely set in, and properly covered over, with neat cement to prevent corrosion, and the abutting course of masonry must be set in cement mortar as ordered by the Engineer. 4. Tie rode of sizes ordered by the Engineer, shall be provided in the end-arches of a roof with arches of equal or nearly equal spans, and in the larger of the unequal spans in arches springing from the same beam. Tie rods must be put in place and the nuts tightened up correctly, before the centerings are fixed. On no account must the centerings be hung from tie rods. 5. The rise of, brick jack arches shall generally be about th 1/12 of the span from 1.0 m to 2.8 m as ordered. 5.1. The jack arch shall be built in the form of a segment of a circle with a rise of about 1/8 of the span. The spacing of joists supporting jack arch terrace shall generally be 1 to 14 m., but shall never exceed 2 m.
Centering
Painting Metal Surface
Tie Rod
Rise
CR Specification No. 907 (para 5) Western Railway Specific ation
Laying
6.1. The bricks for the springing course shall be cut to
CR Specification
27
CHAPTER-IX
template on the ground in sufficient number, before the commencement of the arch. The remaining bricks may not be cut to shape, the radial joint divergence being made good with mortar. The bricks shall be laid with their bed faces (9" X 4 1/2" or 19 cm X 9 cm) normal to the arch thrust. 6.2. The bricks for the springing course shall be cut to template on the ground insufficient number, before the commencement of the arch. The remaining bricks may not be cut to shape, the radial joint divergence being made good with mortar. The bricks shall be laid with their bed faces (9" 4 " or 22.84 cm 11.10 cm) normal to the arch thrust, in the mortar as specified by the engineering, the work in other respects shall conform to Specification No. 20(a) on "Brick workGeneral". 6.3. After the brick arch has set, lime concrete shall be laid and pread so as to have minimum thickness of 80 mm over the crown of arch. 6.4. The lime concrete shall then be consolidated with wooden rammer, weight not exceeding 2 kg. the surface, during the progress of beating, becomes of uneven that water collects in pools, the surface shall be pricked up and fresh concrete added and reconsolidated as necessary. The concrete shall be allowed to harden for a period of not less than six days before applying the floor or roof finish.
Removal Of Centering
No. 907 (para 6)
7. The centering may be removed twelve hours after the completion of the segment of jack arch over it, provided the adjacent jack arches have been completed. 8. When laying concrete over the arches, 12 kg. of castile soap and 4 kg. of alum to each cubic metre of concrete are to be dissolved in the water used for mixing the concrete, or the concrete rendered waterproof by the inclusion of a patent waterproofing powder or solution, as directed by the Engineer. The waterproofing should be duly specified as a special contract condition against this item.
CR Specification No. 907 (para 7) CR Specification No. 907 (para 8)
Water Proofing
f
28

Roofing: Chapter-Ix

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CHAPTER-IX

901 902 903

ROOFING WITH ASBESTOS CORRUGATED SHEETS ROOFING WITH MANGLORE TILES

SPECIFICATION NO. 901 ROOFING WITH ASBESTOS CORRUGATED SHEETS

SPECIFICATION NO. 901 ROOFING WITH ASBESTOS CORRUGATED SHEETS

CR Specificati on No. 901 (para 2) Western Railway Specifi cation

Cuttin g and drilli ng where necess ary

Western Railway Specifi cation

CR Specificati on No. 901 (para 5) CR Specificati on No. 901 (para 8)

CR Specificati on No. 901 (para 3)

Western Railway Specifi cation

Western Railway Specifi cation

Western Railway Specifi cation

Western Railway Specifi cation

Western Railway Specifi cation

Western Railway Specifi cation

Western Railway Specifi cation

Western Railway Specifi cation

Western Railway Specification

Depth of purlin plus

sheets in one horizontal course.

(b) At eaves when

Twice the number of sheets in one horizontal course.

Depth of purlin plus 75 mm

Twice the number of sheet in one horizontal course.

Depth of purlin plus 75 mm

No. of bolt and Bituminous washers and G. I. washer

purlins where horizontal laps do not occur

sheet in one horizontal course plus one.

Western Railway Specific ation

Western Railway Specific ation

Western Railway Specific ation

Western Railway Specific ation

Manufac turers' Instruc tions

Western Railway Specific ation

Western Railway Specific ation

Side LapsCorruga ted Sheets (Big Six)

Western Railway Specific ation

Semicorruga ted Sheets (Traffo rd)

Western Railway Specific ation

LayingCorruga ted Sheets (Big Six )

Western Railway Specific ation

Western Railway Specific ation

Where possible, Manufacturers details should be

CR Specificatio n No. 901 (para 10)

CR Specificatio n No. 901 (para 11)

Western Railway Specific ation

Handlin g and Storage at Site

Western Railway Specific ation

Western Railway Specific ation

SPECIFICATION NO. 902. ROOFING WITH MANGLORE TILES.

SPECIFICATION NO. 902. ROOFING WITH MANGLORE TILES.

Wester n Railwa y Specif icatio n

Wester n Railwa y Specif icatio n

CR Specifica tion No. 903 (para 2)

CR Specifica tion No. 903 (para 3)

CR Specifica tion No. 903 (para 4)

CR Specifica tion No. 903 (para 5)

CR Specifica tion No. 903 (para 6)

Mainte nance by contract or

CR Specifica tion No. 903 (para 7)

CR Specifica tion No. 903 (para 8)